Innovative Design and Computational Fluid Dynamics Analysis Of Electromagnetically Formed Metallic Bipolar Plates for High Performance Proton Exchange Membrane Fuel Cells

Abstract

Abstract The development of bipolar plates is essential for advancing Proton Exchange Membrane Fuel Cells. These plates play a critical role in distributing reactants, conducting electricity, managing heat, and maintaining structural integrity within the fuel cell stack. The efficiency, durability, and cost-effectiveness of fuel cells are directly influenced by flow field design and material selection. This study focuses on the design, computational fluid dynamics analysis, and fabrication of stainless steel 316L bipolar plates using an electromagnetic forming technique. This innovative approach optimizes gas flow distribution and addresses water flooding challenges, enhancing reactant transport and utilization. Stainless steel 316L was selected for its excellent mechanical strength, corrosion resistance, and long-term stability, making it suitable for fuel cell applications. The optimized channel geometry, including depth, width, and surface roughness, improves hydrogen and oxygen delivery while promoting efficient water removal. The electromagnetic forming process ensures uniform flow field distribution and high surface quality by precisely controlling electric discharge voltages through a capacitor bank. By overcoming key challenges in reactant distribution and water management, this research enhances fuel cell performance and reliability, facilitating wider adoption in clean energy applications.